1996 CHRYSLER VOYAGER transmission oil

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on Schedule ± B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter on 2.4L engines.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Change automatic transmission fluid.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
NSLUBRICATION AND MAINTENANCE 0 - 3

52,500 Miles (84 000 km) or at 42 months
²Change engine oil.
²Flush and replace engine coolant if not done at
36 months.
60,000 Miles (96 000 km) or at 48 months
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace, if necessary.
*
²Inspect serpentine drive belt, replace if neces-
sary.
²Inspect tie rod ends and boot seals.
67,500 Miles (108 000 km) or at 54 months
²Change engine oil.
²Inspect brake linings.
75,000 Miles (120 000 km) or at 60 months
²Change engine oil.
²Replace engine oil filter.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
²Change engine oil.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace, if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
97,500 Miles (156 000 km) or at 78 months
²Change engine oil.
100,000 Miles (160,000 km)
²Replace spark plugs on 3.3L and 3.8L
engines.
²Replace ignition cables on 3.3L and 3.8L
engines.
105,000 Miles (168 000 km) or at 84 months
²Change engine oil.
²Replace engine oil filter.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
112,500 Miles (180 000 km) or at 90 months
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
120,000 Miles (192 000 km) or at 96 months
²Change engine oil.
²Replace engine oil filter.
²Replace automatic transmission fluid.
²Replace engine air cleaner element.
²Check and replace PCV valve, if necessary.
*
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
SCHEDULE ± B
3,000 Miles (5 000 km)
²Change engine oil.
6,000 Miles (10 000 km)
²Change engine oil.
²Replace engine oil filter.
9,000 Miles (14 000 km)
²Change engine oil.
²Inspect brake linings.
12,000 Miles (19 000 km)
²Change engine oil.
²Replace engine oil filter.
15,000 Miles (24 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
0 - 4 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)

²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD powertransfer fluid unit.
18,000 Miles (29 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
21,000 Miles (34 000 km)
²Change engine oil.
²Check AWD overrunning clutch and rear carrier
fluid.
24,000 Miles (38 000 km)
²Change engine oil.
²Replace engine oil filter.
27,000 Miles (43 000 km)
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
33,000 Miles (53 000 km)
²Change engine oil.
36,000 Miles (58 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
39,000 Miles (62 000 km)
²Change engine oil.
42,000 Miles (67 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
45,000 Miles (72 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Inspect brake linings.
²Change AWD power transfer unit fluid.
48,000 Miles (77 000 km)
²Change engine oil.
²Replace engine oil filter.
51,000 Miles (82 000 km)
²Change engine oil.
²Flush and replace engine coolant.
54,000 Miles (86 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
57,000 Miles (91 000 km)
²Change engine oil.
60,000 Miles (96 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve, replace if necessary. *
²Inspect serpentine drive belt, replace if neces-
sary.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
63,000 Miles (101 000 km)
²Change engine oil.
²Change AWD overrunning clutch and rear car-
rier fluid.
²Inspect brake linings.
66,000 Miles (106 000 km)
²Change engine oil.
²Replace engine oil filter.
69,000 Miles (110 000 km)
²Change engine oil.
72,000 Miles (115 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
75,000 Miles (120 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
NSLUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

²Replace spark plugs.
²Replace ignition cables.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transaxle fluid and
replace filter. Adjust band, if so equipped. (See note)
²Change AWD power transfer unit fluid.
78,000 Miles (125 000 km)
²Change engine oil.
²Replace engine oil filter.
81,000 Miles (130 000 km)
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant.
84,000 Miles (134 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
87,000 Miles (139 000 km)
²Change engine oil.
90,000 Miles (144 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
93,000 Miles (149 000 km)
²Change engine oil.
96,000 Miles (154 000 km)
²Change engine oil.
²Replace engine oil filter.
99,000 Miles (158 000 km)
²Change engine oil.
²Inspect brake linings.
102,000 Miles (163 000 km)
²Change engine oil.
²Replace engine oil filter.
105,000 Miles (168 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and filter. Adjust bands, if so equipped. (See note)
²Change AWD power transfer unit fluid.
²Change AWD overrunning clutch and rear car-
rier fluid.
108,000 Miles (173 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
111,000 Miles (178 000 km)
²Change engine oil.
²Flush and replace engine coolant.
114,000 Miles (182 000 km)
²Change engine oil.
²Replace engine oil filter.
117,000 Miles (187 000 km)
²Change engine oil.
²Inspect brake linings.
120,000 Miles (192 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped.
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
NOTE: Operating vehicle more than 50% in heavy
traffic during hot weather, above 90ÉF (32ÉC), using
vehicle for police, taxi, limousine type operation or
trailer towing require the more frequent transaxle
service noted in Schedule ± B. Perform these ser-
vices if vehicle is usually operated under these con-
ditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 6 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)

LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION.................. 1
JUMP STARTING, HOISTING AND TOWING . . . 5MAINTENANCE SCHEDULES............... 2
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
ENGINE OIL Ð GASOLINE ENGINES........ 1
ENGINE OILÐDIESEL ENGINES............ 1FLUID CAPACITIES...................... 1
MANUAL TRANSMISSION FLUID
(A-558 and A-598 Models)................ 1
GENERAL INFORMATION
ENGINE OIL Ð GASOLINE ENGINES
Use only oils conforming to API (American Petro-
leum Institute) Quality SJ and Energy Conserving II,
or SH and Energy Conserving II, or ACEA A1±96.
SAE VISCOSITY GRADE
To assure of properly formulated engine oils, it is
recommended that SAE Grade 5W-30 engine oils that
meet Chrysler material standard MS-6395, be used.
SAE Grade 10W-30 oils are also acceptable when the
temperatures do not fall below 0ÉC. In areas where
these grades are not generally available, higher SAE
grades may be used.
Lubricants which have both an SAE grade number
and the proper API service classification shown on
the container should be used.
ENGINE OILÐDIESEL ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationSG/CDorCCMC PD2.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is recom-
mended that SAE Grade 15W-40 engine oils that meet
Chrysler material standard MS-6395, be used. European
Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-30 or 10W-30 grade number
are preferred when minimum temperatures consis-
tently fall below -12ÉC.
MANUAL TRANSMISSION FLUID (A-558 and A-598
Models)
Use only SAE 10W-40 engine oils carrying the
European CCMC-G5 classification to fill the A-598
5±speed manual transmission.
FLUID CAPACITIES
Fuel Tank.............................76L
2.0L Gasoline Engine Oil with Filter........4.3L
2.5L VM Diesel Engine Oil With Filter......6.5L
2.0L Gasoline Engine Cooling System*.......6.0L
2.5L VM Diesel Engine Cooling System*....10.0 L
TransmissionÐ5-Speed Manual............2.2L
* Includes heater and coolant recovery tank filled
to Max level. Add 2.76L if equipped with Rear
Heater.
NS/GSLUBRICATION AND MAINTENANCE 0 - 1

SERVICE PROCEDURES
MASTER CYLINDER FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Master cylinder reservoirs are marked with the
words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder (Fig. 26).
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.When filling master
cylinder fluid reservoir do not fill the filler
neck of the fluid reservoir (Fig. 26) with brake
fluid.
Use only Mopartbrake fluid or an equivalent from
a sealed container. Brake fluid must conform to DOT
3, specifications.
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid ect.
BLEEDING BASE BRAKE HYDRAULIC SYSTEM
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, refer to the
ITT Teves Mark 20 Antilock Brake System bleeding
procedure in the antilock brakes section of this ser-
vice manual.
PRESSURE BLEEDING PROCEDURE
CAUTION: Before removing the master cylinder
cover, throughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
CAUTION: When pressure bleeding the brakes
hydraulic system the fluid reservoir filler neck must
be removed from the master cylinder fluid reservoir.
Failure to remove the filler neck from the fluid res-
ervoir, may result in the filler neck separating from
the fluid reservoir when the hydraulic system is
pressurized.
Follow pressure bleeder manufacturer's instruc-
tions, for use of pressure bleeding equipment.
When bleeding the brake system, some air may be
trapped in the brake lines or valves far upstream, as
much as ten feet from the bleeder screw (Fig. 27).
Therefore, it is essential to have a fast flow of a large
volume of brake fluid when bleeding the brakes to
ensure all the air gets out.
(1) Remove the filler neck from the master cylin-
der fluid reservoir.
(2) Install the Adapter Master Cylinder Pressure
Bleed Cap, Special Tool 6921 on the fluid reservoir of
the master cylinder (Fig. 28). Attach the fluid hose
from the pressure bleeder to the fitting on Special
Tool 6921.
(3) Attach a clear plastic hose to the bleeder screw
at one wheel and feed the hose into a clear jar con-
taining fresh brake fluid.
Fig. 26 Master Cylinder Fluid Level Marks
Fig. 27 Trapped Air In Brake Fluid Line
5 - 20 BRAKESNS

(13) Lower the vehicle to the ground.Be sure
that the suspension is supporting the full
weight of the vehicle.
(14) Tighten the spring to front hanger pivot bolts
to a torque of 156 N´m (115 ft. lbs.).
(15) Tighten the shock absorber mounting bolts to
a torque of 101 N´m (75 ft. lbs.).
(16) Tighten the track bar mounting bolt to a
torque of 95 N´m (70 ft. lbs.).
(17) Road test vehicle to ensure that the prema-
ture rear wheel lockup condition has been corrected.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
Brake System Component Specifications
5 - 82 BRAKESNS
ADJUSTMENTS (Continued)

DESCRIPTION AND OPERATION
CLUTCH RELEASE SYSTEM
CLUTCH CABLE Ð LHD
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear (Fig. 7). This adjuster mechanism is
located within the clutch cable assembly. The preload
spring maintains tension on the cable. This tension
keeps the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
HYDRAULIC CLUTCH Ð RHD
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage to disengage and engage the modular clutch
assembly.
The modular clutch assembly contains the cover,
diaphragm spring, pressure plate, disc and flywheel
in one unit. The modular clutch also uses a drive
plate and is bolted to and driven by the drive plate.
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. The clutch master cylinder push rod is
connected to the clutch pedal and the slave cylinder
push rod is connected to the release lever in the
clutch housing.
Depressing the clutch pedal develops fluid pressure
in the clutch master cylinder. This pressure is trans-
mitted to the slave cylinder through a connecting
line. In turn, the slave cylinder operates the clutch
release lever.
The clutch release bearing is mounted on the
transmission front bearing retainer. The bearing is
attached to the release lever, which moves the bear-
ing into contact with the clutch cover diaphragm
spring.Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc. The
clutch disc is disengaged and not driven at this point.
The process of clutch engagement is simply the
reverse of what occurs during disengagement. Releas-
ing pedal pressure removes clutch linkage pressure.
The release bearing moves away from the diaphragm
spring which allows the pressure plate to exert
clamping force on the clutch disc.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 8).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
Fig. 7 Clutch Cable Ð LHD
Fig. 8 Clutch Pedal Position Switch and
Components Ð LHD Shown
6 - 4 CLUTCHNS/GS